Method for forming or securing unidirectionally-oriented fiber strands in sheet form, such as for use in a ballistic-resistant panel

ABSTRACT

A sheet of unidirectionally-oriented fiber strands includes unidirectional fibers, bonding fibers interwoven with the unidirectional fibers to form a fiber panel, and thermoplastic film laminating the fiber panel there between. In one embodiment, a second sheet of laminated unidirectional fibers is joined to the first sheet of laminated unidirectional fibers with the unidirectional fibers running in a second direction as compared to the first fibers. In yet another embodiment, individual laminated sheets of unidirectional fibers are stitched together to form packets of sheets which may be used singularly or multiple packets may be bundled together.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.09/528,782 filed Mar. 17, 2000, now U.S. Pat. No. 6,562,435, whichclaims the benefit of Provisional application Ser. No. 60/125,403, filedMar. 20, 1999.

TECHNICAL FIELD

This invention relates to forming or securing fiber strands in sheetform and more particularly, to forming or securing fiber strands insheet form for use in a ballistic-resistant laminate.

BACKGROUND OF THE INVENTION

Unidirectional fiber materials are used in ballistic-resistantstructures, and are disclosed, e.g., in U.S. Pat. Nos. 4,916,000,4,079,161, 4,309,487, and 4,213,812. A non-woven ballistic-resistantlaminate referred to by the trademark “Spectra-Shield” is manufacturedby Allied-Signal, Inc. The laminate structure is used in soft body armorto protect the wearer against high-velocity bullets and fragments.“Spectra-shield” was made by first forming a non-woven unidirectionaltape, which was composed of unidirectional polyethylene fibers and anelastic resin material that held the fibers together. The resinpenetrated the fibers, effectively impregnating the entire structurewith the resin product. Two layers, or arrays, of the unidirectionaltape were then laminated together (cross-plied) at right angles to forma panel. The panel was then covered on both sides with a film ofpolyethylene. The film prevented adjacent panels from sticking togetherwhen the panels were layered in the soft body armor. The final panel washeavier and stiffer than desired for use as a ballistic-resistant panel.The weight and stiffness was due in part to the penetration of theentire structure with the resin product.

Non-woven ballistic-resistant laminates without resins are disclosed,e.g., in U.S. Pat. Nos. 5,437,905, 5,443,882, 5,443,883, and 5,547,536.A sheet of non-woven ballistic-resistant laminate structure wasconstructed of high performance fibers without using resins to hold thefibers together. Instead of resin, thermoplastic film was bonded toouter surfaces of two cross-plied layers of unidirectional fibers tohold the fibers in place. The film did not penetrate into the fibers. Asufficient amount of film resided between the bonded layers to adherethe layers together to form a sheet. Bonding the two layers ofunidirectional fibers cross-plied to one another was necessary to meetstructural requirements of the ballistic-resistant panel, such as impactforce distribution. The individual sheets were placed loosely in afabric envelope of an armored garment to form a ballistic-resistantpanel.

SUMMARY

A ballistic-resistant laminate assembly having a plurality of laminateballistic-resistant sheets. Each laminated ballistic-resistant sheethaving a first layer with a plurality of substantially parallel fiberstrands positioned immediately adjacent to each other, the fiber strandsof the first layer having opposing first and second services. A firstlaminating film is adhered to the first surface of the fiber strands ofthe first layer. A second laminating film is adhered to the secondsurface of the fiber strands, with a first and second laminating filmssandwiched in the fiber strands therebetween. The first and secondlaminating films retain the fiber strands in parallel orientation.Adjacent laminating ballistic-resistant sheets are positioned so one ofthe other laminating films from one sheet is immediately adjacent to alaminating film of the adjacent ballistic-resistant. The plurality oflaminated ballistic-resistant sheets are joined together in oneembodiment by stitching the ballistic-resistant sheets together forminga stack of the sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference numbers identify similar elements orsteps. For ease in identifying the discussion of any particular element,the most significant digit in a reference number refers to the Figurenumber in which that element is first introduced (e.g., element 204 isfirst introduced and discussed with respect to FIG. 2).

FIG. 1 is a plan view of a ballistic-resistant unidirectionally-orientedfiber panel including bonding fibers interwoven with the unidirectionalfibers according to one embodiment of the invention.

FIG. 2 is a partial, exploded isometric view of one embodiment includingthermoplastic sheets laminating the unidirectionally-oriented fiberpanel of FIG. 1.

FIG. 3 is a partial, exploded isometric view of another embodiment of alaminated unidirectionally-oriented fiber panel without interwovenbonding fibers.

FIG. 4 is a partial, exploded isometric view of yet another embodimentof a laminated fiber panel including first and second sets of laminated,unidirectionally-oriented fiber panels cross-plied relative to eachtogether.

FIG. 5 is a partial isometric view of several laminatedunidirectionally-oriented fiber panels stitched together to form apacket under one embodiment of the invention.

FIG. 6 is a partial isometric view of another embodiment of severallaminated, unidirectionally-oriented fiber panels stitched together toform a packet.

FIG. 7 is a partial, exploded isometric view of yet another embodimentof several stitched-together packets of laminated,unidirectionally-oriented fiber panels combined to form aballistic-resistant panel.

FIG. 8 is an armored body garment under one embodiment of the invention.

DETAILED DESCRIPTION

The inventors have found limitations and inefficiencies with respect tothe performance and to the manufacturing of the prior artballistic-resistant panels. The laminate gave structure to theunidirectional fibers and served to prohibit adjacent sheets fromsticking together, but it also facilitated movement between the sheets.Thus, the initial impact from, e.g., a bullet, to a ballistic-resistantpanel comprised of loose laminated sheets displaced and rotated thesheets within the pocket such that the antiballistic characteristicswere compromised for subsequent bullets. Additionally, the impact fromthe bullet bunched and pulled the individual fiber strands in the sheetsand further degraded the integrity of the ballistic panel.

When an armor vest is tested in accordance with nationally recognizedstandards, the vest is shot six times at a pre-established distance andin a specific shot pattern. The inventors found with the prior art, thatwhen the bullet pulled the fibers toward entry, the bullet significantlyweakened the areas that fibers were pulled from such that by the fourthand fifth shot, bullets penetrated a raised weakened strike area.Further, in the absence of resins or adhesives, the number of fibers perinch in a panel must be reduced to get opposing laminate sheets to fusetogether. Increasing the density of the fibers to improve ballisticperformance resulted in a panel that delaminated. To form the prior artsheets, fiber spools were unwound as thermoplastic sheets simultaneouslylaminated the fibers to provide alternating layers of fibers andthermoplastic sheets. It was not always feasible, economical orballistically prudent to simultaneously bond the thermoplastic film onone side of the unspooling fibers. Without the thermoplastic film,however, the unspooled unidirectional fibers lacked structure andcollapsed.

Under one aspect of the invention, a unidirectionally-oriented fiberpanel includes unidirectional fibers and bonding fibers interwoven withthe unidirectional fibers to form a unidirectionally-oriented fiberpanel. Under another aspect of the invention, two thermoplastic sheetslaminate the fiber panel between them. Under yet another aspect of theinvention, several of the laminated unidirectionally-oriented fiberpanels are stitched or otherwise bound together to form packets. Methodsfor forming or securing unidirectionally-oriented fiber strands in sheetform are described in detail below. In the following description,numerous specific details are provided, such as specific uses, fiberorientations, numbers of layers, etc., to provide a thoroughunderstanding embodiments of the invention. One skilled in the relevantart will readily recognize that the invention can be practiced withoutone or more of the specific details. In other instances, well-knownstructures or operations are not shown or described in detail to avoidobscuring aspects of the invention.

As illustrated in FIG. 1, a flexible unidirectionally-oriented fiberpanel 110 includes the bonding fibers 130 interwoven with unidirectionalfibers 120. As the unidirectional fibers 120 are unspooled, they may bepassed through a comb guide where the unidirectional fibers are furtherparallelized and spaced into a predetermined uniform density. In oneembodiment, the unidirectional fibers 120 are aramid fibers, with a 1000denier fiber construction and approximately 17 ends/inch unidirectionaluntwisted tows sheet construction. In another embodiment, theunidirectional fibers 120 are aramid fibers, with a 840 denier fiberconstruction and approximately 20 ends/inch unidirectional untwistedtows sheet construction.

As the unidirectional fibers 120 are unspooled to form a fiber sheet110, the bonding fibers 130 are interwoven at an angle with respect tothe unidirectional fiber 120. In the illustrative embodiment, thebonding fibers 130 are interwoven perpendicular to the unidirectionalfibers 120 on approximately one inch centers. Preferably the bondingfibers 130 are spaced one-half inch to two inches, and more preferably,the bonding fibers 130 are evenly spaced one inch apart. In oneembodiment, the bonding fibers 130 are an ethylene vinyl acetate with apolyester core. The coating may be made of natural or man-made polymers,copolymers, waxes or mixtures thereof. Representative examples include,but do not limit the scope of use to the following: styrene, butadiene,polybutadiene, polyvinylchloride, polyethylene, polypropylene, polyvinylacetate (plasticized), acrylics, polyvinyl pyrrolidene compounds,natural latex, paraffin wax of the hot melt type, casein, carboxycellulose esters and ethers. The core may alternatively be constructedout of nylon, cotton or aramid fiber.

After the bonding fibers 130 are interwoven with the unidirectionalfibers 120, they are bonded into a unidirectionally-oriented fiber panel110, for example, with heat and pressure from either static heat or anautoclave. The desired temperature range during heating is preferably upto 500° F., more preferably in the range of 225-375° F., and mostpreferably 265° F. under 45 psi of pressure. In addition to heat bondingthe bonding fibers 130 to the unidirectional fibers 120, bonding can beeffected by other methods depending upon the particular chemicalcomposition of the fiber's coating. For example, bonding can be done bymoisture, the use of organic solvents, high-pressure alone, or contactpressure. Such bonding techniques, however, should not adversely affectthe unidirectional fibers 120 or destroy the configuration of the fibersthat the bonding fibers 130 are to reinforce. Further, the coating ofthe bonding fibers 130 must bond with whatever surface coating orlaminate is to be applied to the unidirectionally-oriented fiber panel110.

Interweaving the bonding fibers 130 with the unidirectional fibers 120allows the fiber panel 110 to be handled, transported, and processedeither at a different location or at a later time. This feature providesadvantages, including both efficiency and economy. Under traditionalmanufacturing methods, it was necessary to secure the thermoplastic filmonto one side of the fibers at the same time the unidirectional fiberswere unspooled to provide structure for the unidirectional fibers and topreserve the sheet configuration of the fibers. The bonding fibers 130provide this structure to the unidirectional fibers 120. Thus, athermoplastic film may be laminated to the unidirectional fibers 120either at the same time as the unidirectional fibers 120 are unspooledor at a later time.

As illustrated in FIG. 2, lower and upper thermoplastic films 240 and242, respectively, are provided on top and bottom sides of the singlefiber panel 110, and then secured or laminated thereto so theunidirectionally-oriented fibers are securely sandwiched between thefilms.

In one embodiment, the thermoplastic films 240 and 242 are extremelythin, typically less than 0.35 mils to maintain the flexibility of thelaminated fiber ballistic-resistant panel. Alternatively, thicker filmsup to approximately 0.5 mils may be used to form a laminated fiber panelof greater rigidity. In one embodiment, the film will slightly coat theexterior surfaces of the unidirectional fibers 120 to encapsulate them,but will not impregnate the fibers. Sufficient plasticized film materialflows between adjacent fibers 120 to bond the thermoplastics film 240and 242 to the unidirectional fibers 120. The thermoplastic films 240and 242 may be a polyethylene film. Due to the structure provided bybonding fibers 130, the thermoplastic films 240 and 242 may be laminatedover the unidirectional fiber panel 110 either as the unidirectionalfibers 120 are unspooled and interwoven with the bonding fibers 130 orat a later time. The thermoplastic films 240 and 242 laminate to eachside of a panel 110 of unidirectional fibers 120 to form a flexiblelaminated unidirectionally-oriented fiber sheet 205. These flexiblesheets 205 may be used individually or may be combined with other sheetsas described below, to form a variety of items includingballistic-resistant panels.

The bonding fibers 130 further provide structure to which thethermoplastic films 240 and 242 can bond. Because the thermoplasticfilms 240 and 242 bond with the interwoven bonding fibers 130, the fiberpanel 110 may contain a greater density of unidirectional fibers 120.The bonding fibers 130 of this embodiment thus provide at least twofunctions: the bonding fibers 130 help prevent the unidirectionallyoriented fiber panel from spreading or delaminating before and after thethermoplastic films 240 and 242 laminate it, and the bonding fibers 130provide the panel enhanced buoyant characteristics. The greater thedensity of the fibers 120 in the panel, the greater the amount of airthat may be trapped between the fibers when the fiber panel 110 islaminated between the films 240 and 242. The bonding fibers 130 allowthe density of the fibers 120 to be maximized by giving the fiber panel110 further structure while preventing delamination of the laminatedfiber panel by bonding with the thermoplastic film. The bond between thethermoplastic sheets 240 and 242 and the bonding fibers 130 createequally spaced sealed pockets of air which when used in a ballisticpanel, produces buoyant ballistic panels.

Alternatively, if sufficient heat, or heat with sufficient pressure fora sufficient duration, is applied to the thermoplastic film 240 to meltthe film 240 and 242 into the unidirectional fiber 120, a semi-rigid orrigid structure (not shown) is formed. Before heating the thermoplasticfilms 240 and 242, the laminated unidirectional fiber sheet 205 may beconfigured into any variety of shapes. This semi-rigid or rigidstructure may be used alone or may be used in combination with otherpanels to form any variety of items including but not limited to cargoboxes, storage boxes, aircraft containers, water skis, snow skis, hockeysticks, vehicle bodies such as boat hulls, and protective elements suchas helmets for racing, military use or bicycling.

As illustrated in FIG. 3, an alternative embodiment includes a panel 310of unidirectionally-oriented fibers 120 with lower and upper sheets ofthermoplastic film 240 and 242 provided on a top and bottom surface ofthe fiber panel 310 to form a flexible laminatedunidirectionally-oriented fiber sheet 305. This single layerunidirectional fiber panel 310 laminated on both sides by thermoplasticfilm 240 and 242 provides a sheet 305 with maximum flexibility whileproviding sufficient structure to prevent degradation of theunidirectional fiber sheet's 120 configuration. This unidirectionalfiber panel 310 may be used individually or in combination with otherfiber panels disclosed herein. Alternatively, the thermoplastic film 240and 242 may be heated such that the thermoplastic film 240 and 242 willmelt and encapsulate or impregnate the individual fiber strands 120resulting in a rigid sheet (not shown).

The decision to produce either a rigid or a flexible fiber sheet istypically dictated by the end use of the fiber sheet. Two or more sheets305, such as the sheets used to form ballistic-resistant panels, forexample, require flexible, pliable sheets for the wearer's comfort,while providing ballistic protection. Several sheets 305 used to formhelmets, for example, require rigid sheets configured to fit thewearer's head.

As illustrated in FIG. 4, yet another alternative embodiment bonds alaminated unidirectional fiber panel 205 with unidirectional fibers 120oriented in a first direction (as illustrated in FIG. 1) with a secondlaminated unidirectional fiber panel 205 having unidirectional fibers120 oriented in a second direction. As illustrated, the panels 205 eachinclude bonding fibers 130 positioned perpendicular to theunidirectional fibers 120 and interwoven with the unidirectional fibers120. As discussed with respect to FIGS. 1 and 2, the bonding fibers 130provide structure to the unidirectional fibers 120 and allow the panel110 to be manufactured without the thermoplastic film 240 or 242.Alternatively, if the thermoplastic film 240 or 242 is bonded to eithera first or a second surface when the unidirectional fiber 120 isunspooled to form a panel, then the thermoplastic film 240 and 242 maybe used to provide the structure to the panel and the bonding fibers 130may be omitted.

When the unidirectional fibers 120 are interwoven with the bondingfibers 130 and layered between thermoplastic sheets 240 and 242 andlaminated to produce a flexible sheet 405, the flexible sheet 405 hasunexpected advantages, such as being easy to handle without damaging,loosening, or substantially degrading the effectiveness of theunidirectional fibers. The laminated structure is also quite buoyantbecause air is trapped within the sheet between the film. Thischaracteristic is important for various end uses of the panels, forexample, for use in a floatation device.

As illustrated in FIG. 5, yet another embodiment of the presentinvention includes several of [any one of] the unidirectionally-orientedfiber panels 405 stacked on top of one another with the fibers of eachpanel selectively oriented relative to the fiber of adjacent panels,such as parallel, perpendicular, or at other angles. The stack of panels405 are secured together by stitches 560 to form a packet 550. In analternate embodiment, adjacent panels 405 can be secured together withan adhesive provided between the adjacent thermoplastic films of twopanels. The adhesive can be applied in selected patterns on the facingsurfaces of the films, so as to control the stiffness or rigidity of theresulting stack of panels. The stack of panels 405 adhered together canalso be stitched together at selected locations or patterns as neededfor the particular application for which the packet 550 is to be used.Further, any one of the sheets illustrated in FIGS. 1-4 may be used inany combination to form the packet 550. Specifically, when using theunidirectionally-oriented fiber panel 405 illustrated in FIG. 4 to formthe packet, preferably three to eight panels 405 are sewn together toform a packet 550, more preferably four to six panels 405, and mostpreferably five panels are used to form a packet 550. When using theunidirectionally-oriented fiber sheet 205 or 305 (FIGS. 2 or 3) to formthe packet for use in a ballistic panel, the sheets are placed such thatthe orientation of fibers is rotated a selected angle with respect toadjacent sheets.

Stitching the sheets 550 together to form packets 550 provides at leastone unexpected result of providing improved resistance to ballisticpenetration in a ballistic panel with fewer total fiber panels required,as described below. In one embodiment, preferably four to ten packets offiber sheets 405 are used to form a ballistic panel, more preferablyfour to eight packets and most preferably six packets are used to form aballistic panel. When a bullet hits a ballistic-resistant panel, thebullet penetrates the initial layers and the impact force of the bulletdisplaces secondary layers. When the ballistic panel is made up ofseveral individual unidirectionally-oriented fiber sheets, the force ofthe bullet causes some fibers in the panel to push apart and separate,and other fibers at the tip of the bullet to bunch. Adjacent fibers thatthe bullet doesn't actually penetrate are pulled out of position andweakened by the impact force of the bullet. This creates a path ofreduced resistance through the panel. The result is that the integrityof the ballistic-resistant panel is significantly impaired after thefirst impact. Packets of unidirectionally-oriented fiber sheets retainthe benefit that the movement between the individual sheets allows, i.e.shifting the bullet off course and diffusing the straight linepenetration of the bullet, while decreasing the penetration and thebunching caused by the bullet. The packets act like individual panelswithin the ballistic-resistant panel in that each individual packet actsindependently of the adjacent packet. Thus the bullet's trajectoryangles at each packet so that it doesn't create a path through thepanel.

Fewer sheets are used to form a ballistic-resistant panel of equivalentcharacteristics compared to prior systems, therefore the resultant panelis more flexible and lighter in weight. When a bullet impacts aballistic-resistant panel, the panel is subject to both the impact forceof the bullet and a reverberating energy wave sent out ahead of thebullet. The components of the packet of this embodiment combine toprovide a more efficient ballistic-resistant panel. Components includeany one of or a combination of the following: density of theunidirectional fibers in the panel, bonding thread, the cross-pliedpositioning of the fiber panels, thermoplastic films, the laminatedfiber panels stitched together in packets, and the interaction betweenthe individual packets combine in a cooperative effort to provide animproved ballistic-resistant panel. Among other things, sewing thesheets in packets maximizes the anti-ballistic properties of theindividual sheets such that the resultant packet is stronger than thesum of the individual sheets. Additionally, as fewer sheets arerequired, the ballistic-resistant panel is less expensive tomanufacturer.

Stitching the sheets 405 to form a packet 550 may be done by any varietyof stitching patterns and is illustrated in FIG. 5 as a diamond pattern.An alternative pattern includes vertical stitching perpendicular to theunidirectional fibers. Vertical stitching helps prevent the fibers frompulling side to side. Vertical stitches are preferably evenly spaced,more preferably evenly spaced 2″-4″ apart and most preferably evenlyspaced 3″ apart. Stitching patterns may also include perimeterstitching, continuous and noncontinuous patterns, and any other varietyof stitching patterns. In addition to stitching to secure the sheetstogether to form a packet, any one of a number of devices including butnot limited to the following may be used: staples (permanent plastic ormetal); dry or wet adhesive applied directly or on strips such asdouble-sided tape; various patterns of bar tacks; interlocking tabs inthe sheets themselves or slots in the laminate; heat fusible thread onthe exterior of select sheets; stacking two or more thermoplastic filmsand applying heat while pressing them together and taking advantage ofthe “sticky” properties of the film element of the laminate; fine Velcroor similar hook and loop material between the layers of sheets, snaps,any permutations and/or combinations of all of the above devices;induced static electrical charge; and interwoven magnetic material.Additionally, a wide variety of materials may be used for the stitchingthread including natural and manmade fiber threads, polymer-basedthreads (such as fishing line), fine steel or other metal or compositeor alloy wire, racket sports string (including natural, such as catgut,and synthetic materials).

FIG. 6 illustrates an alternative embodiment of a packet 650 of severalunidirectionally-oriented fiber sheets affixed together. As discussedabove, any combination of sheets may be used to form the packet 650,including but not limited to, this illustrated combination layering 405,305, 205, 305 and 405. As the individual sheet configurations havespecific features or strengths, the positioning of the sheets within thepacket will serve to highlight those features or strengths.

As illustrated in FIG. 7, the packets 550 or 650 are combined to form aballistic-resistant panel 704. As is further illustrated in FIG. 8, oneor more packets 550 or 650 can be bundled together and inserted inpockets 806 to form a ballistic-resistant panel 704. Thisballistic-resistant panel 704 may be used as illustrated in a structuresuch as a vest 802. The packets increase ballistic-resistant efficiencyby helping to hold the sheets in position. Traditionally, the firstimpact or shot to the ballistic-resistant panel 704 caused displacementand rotation of the sheets, which resulted in a less efficientballistic-resistant panel 704 for second or subsequent sheets. Thestitching 560 or otherwise securing the individual sheets to formpackets 550 or 650, and then bundling the packets 550 or 650 together toform a ballistic-resistant panel 704, reduces the shifting and rotationcaused by the initial shot.

The impact of the bullet indents the ballistic-resistant panel andcauses some of the fibers in the ballistic-resistant panel to compact atthe front of the bullet while stretching and pulling other fibers out ofposition as the bullet moves through the ballistic-resistant panel.Additionally, the indentation from the force of the bullet in theballistic-resistant panel in one location causes a resulting protrusionof the panel's flat surface surrounding the indentation. This protrusioncan buckle the surface of the entire panel depending on the entrylocation of the bullet. This buckling creates an air pocket between thepanel and the wearer's chest which in turn impacts the integrity of theentire ballistic-resistant panel.

The various embodiments described above can be combined to providefurther embodiments. All of the above U.S. patents and applications areincorporated by reference. Aspects of the invention can be modified, ifnecessary, to employ the systems, circuits and concepts of the variouspatents and applications described above to provide yet furtherembodiments of the invention.

These and other changes can be made to the invention in light of theabove detailed description. In general, in the following claims, theterms used should not be construed to limit the invention to thespecific embodiments disclosed in the specification and the claims, butshould be construed to include all unidirectionally-oriented fibersheets that operate under the claims. Accordingly, the invention is notlimited by the disclosure, but instead its scope is to be determinedentirely by the following claims.

1. A ballistic-resistant laminate assembly, comprising: a substantiallyplanar, non-woven first layer having a plurality of unidirectional fiberstrands positioned adjacent to each other, the fiber strands of thefirst layer forming generally opposing first and second surfaces; afirst laminate film adhered to the first surface of the first layer'sfiber strands; a second laminate film adhered to the second surface ofthe first layer's fiber strands, with the first and second laminatefilms sandwiching the fiber strands therebetween and retaining the firstlayer's fiber strands in parallel orientation, the first layer and thefirst and second laminate films forming a first laminatedballistic-resistant sheet; a substantially planar, non-woven secondlayer having a plurality of unidirectional fiber strands positionedadjacent to each other, the fiber strands of the second layer forminggenerally opposing third and fourth surfaces; a third laminate filmadhered to the third surface of the second layer's fiber strands; and afourth laminate film adhered to the fourth surface of the second layer'sfiber strands, the third and fourth laminate films sandwiching thesecond layer's fiber strands therebetween and retaining the secondlayer's fiber strands in parallel orientation, the second layer and thethird and fourth laminate films forming a second laminatedballistic-resistant sheet, the second laminated ballistic-resistantsheet being joined to the first laminated ballistic-resistant sheet withone of the third and fourth laminating films and one of the first andsecond laminate films separating the first and secon fiber strands ofthe first and second layers.
 2. The ballistic-resistant laminateassembly of claim 1 wherein the fiber strands of the first and secondlayers are aramid fibers.
 3. The ballistic-resistant laminate assemblyof claim 1, wherein the first layer further includes a plurality ofbonding fibers spaced apart from each other by a selected distance andconnected to the fiber strands, the bonding fibers being positioned at apredetermined angle relative to the fiber strands, the bonding fibersbeing sandwiched between the first and second laminate films.
 4. Theballistic-resistant laminate assembly of claim 3 wherein the bondingfiber strands are an ethylene vinyl acetate with a polyester core. 5.The ballistic-resistant laminate assembly of claim 3 wherein the bondingfiber are substantially perpendicular to the first layer's strands. 6.The ballistic-resistant laminate assembly of claim 1 wherein the firstand second laminate films are thermoplastic.
 7. The ballistic-resistantlaminate assembly of claim 1, wherein the first and secondballistic-sheets are stitched together.
 8. The ballistic-resistantlaminate assembly of claim 1, wherein first layer's fiber strands areoriented at a selected angle relative to the second layer's fiberstrands.
 9. The ballistic-resistant laminate assembly of claim 1,wherein the first layer's fiber strands are perpendicular to the secondlayer's fiber strands.
 10. The ballistic-resistant laminate assembly ofclaim 1 wherein the first and second laminated ballistic-resistantsheets are joined with a plurality of other unidirectional laminatedballistic-resistant sheets for form a multi-layer, ballistic-resistantpanel.
 11. A multiple-layer ballistic-resistant panel comprising: afirst unidirectionally-oriented fiber strand laminate sheet including aplurality of unidirectional first fiber strands positioned substantiallyparallel to each other and forming generally opposing first and secondsurfaces, a first laminate film adhered to the first surface, and asecond laminate film adhered to the second surface, with the first andsecond laminate films sandwiching the first fiber strands therebetween;a second unidirectionally-oriented fiber strand laminate sheetpositioned immediately adjacent to the first laminate sheet having aplurality of unidirectional second fiber strands positionedsubstantially parallel to each other and forming generally opposingthird and fourth surfaces, a third laminate film adhered to the thirdsurface, and a fourth laminate film attached to the fourth surface, withthe third and fourth laminate films sandwiching the second fiber strandstherebetween; and a joining member securely retaining the first andsecond fiber strand laminate sheets together with one of the first andsecond laminate sheets being immediately adjacent to one of the thirdand fourth laminate sheets.
 12. The ballistic-resistant panel of claim11 wherein the joining member is a stitching thread.
 13. Theballistic-resistant panel of claim 11 wherein the first fiber strandsare oriented at an angle of 90 degrees relative to the second fiberstrands.
 14. The ballistic-resistant panel of claim 11, wherein thefirst fiber strands are oriented at a selected angular orientationrelative to the second fiber strands.
 15. The ballistic-resistant panelof claim 11, wherein the joining member is stitching forming a diamondpattern on one of the first and second laminate sheets.
 16. Theballistic-resistant panel of claim 11, wherein the first and secondlaminate films are thermoplastic.
 17. The ballistic-resistant panel ofclaim 11, wherein the first fiber strands are aramd fibers.